Nissan Cuts Annual Cooling Costs by $490,000 with tekWorx Chiller Plant Optimization Solutions

Nissan Cuts Annual Cooling Costs by $490,000 with Xpress®

tekWorx converted the plant’s hydronic configuration to an Integrated Primary-Secondary® (IPS) design and used adaptive control algorithms to provide additional energy savings, save kWh and improve operational efficiencies.

Facility Bio

  • Canton, MS
  • 4.7 million ft²
  • Manufactures Altima, Titan and Murano vehicles
  • 10 x 2,500 ton chillers


  • Corporate energy initiatives to reduce energy spending prompted optimization projects
  • Plant configured using an inherently inefficient Primary/Secondary hydronic design
  • Existing control system was functional, but had no optimization sequence in place
  • Plant controls were being operated manually


  • Convert plant hydronic configuration to Integrated Primary-Secondary® (IPS)
  • Implement Xpress® optimization platform on Nissan standard PLC
  • Xpress® adaptive algorithms continuously adjust system operation in real-time, maximizing overall plant efficiency

Results That Exceed Client Expectations

Financial Savings

  • $490,000 annual savings
  • 1.5-year payback

Energy Impact

  • 8,500,000 kWh saved annually

Operational Benefits

  • Less equipment wear and tear
    Operators freed up for other tasks
  • Automated system controlling all plant equipment
  • Chiller health monitoring system provides alerts for preventive maintenance actions
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